VR46.5V(A)/VR86.5V(A) SERIES COMACT COMBINATION GAS CONTROS WITH INTEGRATED 1:1 GAS/AIR REGUATOR FOR AUTOMATIC IGNITION SYSTEMS SECIFICATIONS INSTRUCTION SHEET Subject to change without notice. rinted in the Netherlands. AICATION are used in a system context in conjunction with fan control, a direct spark ignition (DSI) control module and associated devices to provide programmed safe light--up and supervision of the main burner of an appliance. are intended to be used for natural gas. are approved in accordance with existing european standards. DESCRITION perform all the functions required to safely regulate gas flow to the main burner of domestic central heating equipment, warm air furnaces, back boilers and water heaters. VR46.5V(A)/VR86.5V. compact combination gas controls consist of a first direct electric ON/OFF operator for opening the safety valve of class A or B according to EN 161 and a second electric ON/OFF servo operator valve for opening the main valve of class C or J according to EN 161. Models VR46.5 /VR86.5 series: two automatic shut off valves for direct spark ignition (DSI) or hot surface ignition (HSI) applications. VR46.5 series line voltage VR86.5 series low voltage Suffix letter V: fast opening, with integrated 1 : 1 gas/air regulation, medium capacity. VA:fast opening, with integrated 1 : 1 gas/air regulation, low capacity Dimensions See fig. 1. Ambient temperature Suffix V: 0... 60 _C Suffix VA: 0... 70 _C ressure regulation function Class C according to EN 88 ipe size ipe connections are designed to meet the bending stress of group 2 according to EN 161. Standard: Inlet and outlet: 1 / 2 ISO 7--1 internal parallel pipe thread. Inlet and outlet can also be made with straight or elbow flanges. Air pressure connection Servo pressure regulator has an M5 threaded hole to make connection between regulator and appliance. Maximum air pressure 8 mbar without outlet gas pressure (before ignition) 20 mbar with outlet gas pressure present (after ignition) Minimum regulation capacity across the main burner injector at,p=0.5 mbar Model Maximum operating pressure (mbar) VR46.5VA... 30 0.5 VR86.5VA... VR8645V 1003 60 0.7 VR8615V 1006 30 1.5 VR8645V 1011 Minimum regulation capacity (m 3 air/ h )
B 31 75 A 58 64 29 21 22 24 25 C 92 D E F G O H 115 J K 118 F 69 37 d * 1 / 2 d 127 21 M * d=30-- 1 / 2 ISO7--1 * d=-- 3 / 4 ISO7--1 N 5.5 A -- Cap screw/offset adjustment screw B -- 6.3 AM terminals C -- Inlet pressure tap D --Throttle adjustment screw E -- Outlet pressure tap F -- Gas pressure tap upstream of throttle (throttle versions only) G -- M5 air pressure connection H -- Terminals according to DIN 450 J -- Inlet K -- Outlet -- M5 mounting holes for mounting the flange M -- M5 mounting holes for mounting the valve N --Surfacetobeclamped O -- Outlet pressure tap (VR8615V 1006/VR8645V 1011 only) Fig. 1. Adjustment points and dimensions Minimum operating gas pressure 15 mbar Offset range -- 0.4 mbar... + 0.2 mbar combination gas control in 90_ from upright position (first coil horizontal) -- 0.25 mbar... + 0.2 mbar combination gas control in upright position (first coil vertical) Maximum operating gas pressure The max 60 mbar indication on the housing is the maximum inlet pressure at which the combination gas control functions safely. High inlet pressures as used for gas G30 or G31, can cause oscillation. This is dependent on type of appliance. The oscillation shall not exceed 10 % of the outlet pressure, measured at maximum inlet pressure according to EN 483. The oscillation has to be verified for the complete modulation band of the appliance. lease contact your Honeywell representative if the maximum of 10 % is exceeded. Oscillation outlet pressure to be recorded with oscilloscope etc. via transducer without damping. 2
Capacity Timing In m 3 /h air; measured with throttle open, Closing time: ±1 s 1013 mbar and 15 _C. Curves are available on request. Opening time: ±1 s from start of flow till outlet pressure Model,p (mbar) Capacity is1 mbar. VR4615VA/VR8615VA 1) 10 4.2 Enclosure VR4645VA/VR8645VA 2) 10 4.2 I 40: when used with covers or plugs I 44: when used with DIN plugs according to DIN 450 VR4615V/VR8615V 10 5.4 Valve classification VR4645V/VR8645V 3) 10 5.4 Type Class Exceptions 1 st valve 2 nd valve Model,p (mbar) Capacity VR4615 Class B Class C 1) VR8615VA 1012 10 5.4 VR8615 1) VR8615V 1006 7.5 5.4 VR4645 Class A Class C VR8645 2) VR8645V 1011 7.5 5.4 Mounting holes 3) VR4645V 1015 10 4.2 Two M5 mounting holes are located on the bottom of the combination gas control. The four holes at inlet and outlet side for mounting the flange to the combination gas control are provided with M5 thread with min. 6.5 mm full thread. Electrical data Model Nominal voltage ower consumption at nominal voltage (W) Current at nominal voltage (ma) VR8615VA VR8615VA VR4615VA VR4615VA 24 V, 60 Hz 220/240 V, 50 Hz 220 V, 60 Hz 1 st operator 2 nd operator 1 st operator 2 nd operator 4.9 3.6/4.7 4.9 4.7 3.4/4.5 280 400 32/ 45 266 20.4/24 21.1 VR8645VA 4.8 420 VR8615V VR8615V VR4615V VR4615V 24 V, 60 Hz 220/240 V, 50 Hz 220 V, 60 Hz 7 8.3 6.5/8 8.3 4.7 3.4/4.5 450 550 50/60 57 266 20.4/24 21.1 VR8645V 10 700 VR8615V 1006 7 2.1 450 121 VR8615V 1011 10 2.1 700 121 3
1 2 3 4 5 7 8 9 10 11 12 13 14 16 V 1 V 2 V 1 N T p T p T s Thermostat Gas valve Ignition Flame rod Fan imiter Reset switch Flame indication Alarm Air proving relay switch INSTAATION IMORTANT Take care that installer is a trained experienced service person. Turn off gas supply before starting installation. Disconnect power supply to prevent electrical shock and/or equipment damage. Do not remove seals over inlet and outlet until the device is ready to be installed. If M5 air pressure connection is not to be used, it is recommanded to push a dust cap into the hole (order nr. 45.900.426-001). Mounting position The combination gas control can be mounted 0 to 90_ in any direction from the upright position, i.e. from the position when electric operators are on top. Main gas connection Take care that dirt cannot enter the combination gas control during handling. Use a clean taper fitting with thread according to ISO 7--1 or a piece of new, properly reamed pipe, free from swarf. Do not tighten the pipe or pipe fitting too far (see table below). Otherwise valve distortion and malfunction could result. ipe size Max. length of pipe thread 1 / 2 18.6 mm Apply a moderate amount of good quality thread compound to the pipe or fitting only, leaving the two end threads bare. TFE tape may be used as an alternative. Ensure that gas flows in the same direction as the arrow on the bottom of the combination gas control. Fig. 2. Functional diagram and wiring of S4560 Electrical connection CAUTION Switch off power supply before making electrical connections. Take care that wiring is in accordance with applicable codes and local regulations. To ensure a safe closing of the valve, it is essential that the voltage is reduced to 0 Volt. Ensure that cut -off function of limit control de -energizes both valves. Use lead wire which can withstand 105 _C ambient. The electric on/off operator is provided with: 6.3 mm quick connect terminals suitable for 6.3 mm receptacles (e.g. Series 250 AM fasteners) and special plugs. The electric servo on/off operator/regulator is provided with: quick connect terminals suitable for a female connector according to DIN 450 and special plugs. Wiring combination gas controls in direct spark ignition (DSI) systems The appliance manufacturer s instructions should always be followed when provided. If not available see fig. 2. for typical systems using Honeywell S4560 ignition control. Tightness test after installation aint all pipe connections and gaskets with a strong soap and water solution. Do not use an aggressive soap. Start the appliance and check for bubbles. If a leak is found in a pipe connection, remake the joint. A gasket leak can usually be stopped by tightening the mounting screws. Otherwise, replace the gasket. Be careful not to clog bleed vent parts with soap solution residue. Remember bleed vents will discharge air during gas valve opening or closing giving false indication of leakage. 4
ADJUSTMENTS Adjustments must be made by qualified persons only. If the appliance manufacturer supplies checkout and/ or service and maintenance instructions carefully follow them. If such instructions are not provided then use the procedure outlined below. Adjustment can only be made with a special tool. ressure tap The combination gas control is provided with a pressure tap of 9 mm outer diameter at inlet and outlet side. The combination gas control with throttle valve have an extra pressure tap to measure the gas pressure upstream of the throttle valve. When checking the pressure undo the screw a half turn and slip tube over nipple. Ensure that screw is retightened after making test. CAUTION To ensure a safe closing of the valves, it is essential that voltage over the terminals of electric operators is reduced to 0 Volt. To prevent gas leakage mount the gas pressure tap upstream the throttle (see fig. 1. F ) before gas is connected to the combination gas control. Offset adjustment servo regulated versions (see fig. 1.) Remove cap screw with a screw driver to expose offset adjustment screw. Check gas supply pressure to the appliance using a pressure gauge connected to the inlet pressure tap. Start fan and check air flow. Energize both electric operators in order to have gas input to burner and ignite boiler. Adjust CO 2 % at the desired value at low output with offset adjustment screw.turn offset adjustment screw clockwise to increase CO 2 %. Operate boiler on high output. (Only modulating applications). Replace cap screw and tighten pressure taps. Offset adjustment throttle valve versions on modulating applications (see fig. 1.) Remove cap screw with a screw driver to expose offset adjustment screw. Check gas supply pressure to the appliance using a pressure gauge connected to the inlet pressure tap. Start fan and check air flow. Energize both electric operators in order to have gas input to burner and ignite boiler. Adjust the CO 2 % at the desired value at low output with offset adjustment screw. Turn offset adjustment screw clockwise to increase CO 2 %. Operate boiler on high output. Turn the throttle adjustment screw with a until the burner pressure required is recorded on the pressure gauge. Adjust CO 2 % with throttle adjustment screw at the desired value. Turn screw driver either way to increase CO 2 %. Replace cap screw and tighten pressure taps. CHECKOUT Final checkout of the installation After any adjustment check pressure taps and gas connections with an approved leak detection fluid for gas leakage. After any adjustment set appliance in operation and observe several complete cycles to ensure that all burner components function correctly. MAINTENANCE Maintenance and service Under normal circumstances no maintenance or service is required. Screws on the valve that have been sealed must never be removed. Home and Building Control Combustion Controls Center Europe Honeywell BV hileas Foggstraat 7 7821 AJ Emmen The Netherlands Tel: +31 ( -)591 695911 Fax: +31 ( -)591 695200 http://europe.hbc.honeywell.com 5